Yamaha WaveRunner FX Cruiser SHO Manuals

Manuals and User Guides for Yamaha WaveRunner FX Cruiser SHO. We have 1 Yamaha WaveRunner FX Cruiser SHO manual available for free PDF download: Service Manual

Yamaha WaveRunner FX Cruiser SHO Service Manual

Yamaha WaveRunner FX Cruiser SHO Service Manual (433 pages)

Brand: Yamaha | Category: Boat | Size: 16.68 MB

Table of Contents

Table of Contents

3
- Lit-18616
  2
- Chapter 1
  
  6
  - How to Use this Manual
    6
  - Manual Format
    6
  - Contents
    7
    
    Abbreviation
    8
    
    Grease Table
    8
  - Symbols
    7
  - Safety While Working
    9
    
    Fire Prevention
    9
    
    Parts, Lubricants, and Sealants
    9
    
    Self-Protection
    9
    
    Ventilation
    9
    
    Disassembly and Assembly
    10
    
    Good Working Practices
    10
  - Identification Number
    11
    
    Engine Serial Number
    11
    
    Hull Identification Number (H.l.n.)
    11
    
    Jet Pump Unit Serial Number
    11
    
    Primary L.D. Number
    11
  - Special Service Tool
    12
    
    Measuring
    12
    
    Removal and Installation
    14
  - Feature and Benefit
    19
    
    Watercraft Overview
    19
    
    Engine Overview
    20
    
    Air Filter Case and Air Filter Element
    21
    
    Supercharger Assembly
    21
    
    Air Cooler Assembly
    22
    
    Intake System
    22
    
    Electronic Control Throttle Valve (ETV) System
    23
    
    Cylinder Head Assembly
    24
    
    Hydraulic Timing Chain Tensioner
    24
    
    Ignition Coil
    25
    
    Piston and Connecting Rod
    25
    
    Cylinder Block and Crankcase
    26
    
    Knock Sensor
    26
    
    Lubrication System
    27
    
    Oil Pump Assembly
    28
    
    Oil Pan
    29
    
    Oil Cooler Assembly
    30
    
    Oil Separator Tank
    30
    
    Exhaust System
    31
    
    Oil Filter
    31
    
    Cooling System
    32
    
    Water Cooled Rectifier Regulator
    33
    
    In-Tank Fuel Pump Module
    34
    
    Intake Grate
    35
    
    Large Intermediate Housing and Oil Seal
    35
    
    Qsts
    36
    
    Reverse Gate Assembly
    36
    
    Multifunction Meter
    37
    
    Right Multifunction Display (FX Cruiser SHO)
    40
    
    Average Speed, Tripmeter, and Trip Time Measurements
    41
    
    Cruise Assist and No-Wake Mode
    42
    
    Electrical System
    42
    
    Yamaha Diagnostic System (YDIS)
    42
    
    Slant Detection Switch
    43
    
    L-MODE (Low-Rpm Mode) and Yamaha Security System
    44
    
    Off-Throttle Steering (OTS) System
    44
    
    Remote Control Transmitter
    46
  - Technical Tips
    47
    
    Engine Control
    47
    
    Cruise Assist Control
    48
    
    No-Wake Mode Control
    49
    
    Idle Speed Control
    50
    
    L-MODE (LOW-RPM MODE) Control
    50
    
    Over Revolution Control
    50
    
    Reverse with Traction Control
    50
    
    Slant Detection Control
    50
    
    High Intake Air Pressure Control
    51
    
    Knock Control
    51
    
    Off-Throttle Steering (OTS) Control
    52
    
    Remote Control Transmitter Control
    53
    
    ETV Failure Control
    54
    
    Oil Pressure Warning Control
    54
    
    Overheat Warning Control
    54
    
    Warning Control
    54
    
    Battery Disconnection Warning
    55
    
    Cam Position Sensor Failure Control
    55
    
    Fail-Safe Function Table
    56
Chapter 2 Specification

59
- Fuel
  60
  - Maintenance Specifications
    62
    
    Engine
    62
    
    Fuel System
    65
    
    Electrical
    66
    
    Hull and Hood
    66
    
    Jet Pump Unit
    66
  - Tightening Torques
    70
    
    Specified Torques
    70
    
    General Torque
    76
  - Cable and Hose Routing
    77
    
    Starboard Bow View
    77
    
    Top View
    78
    
    Port View
    80
- General Specification
  60
Adj Chapter 3 Periodic Check and Adjustment

83
- Maintenance Interval Chart
  84
- Chapter 3
  
  85
  - Jet Thrust Nozzle Steering Angle Check and Adjustment
    85
  - Periodic Service
    85
    
    Control System
    85
  - Steering System Check
    85
  - Jet Thrust Nozzle QSTS Angle Check and Adjustment
    87
  - Throttle Lever Free Play Check and Adjustment
    88
  - Shift Cable Check and Adjustment
    90
  - Trolling Speed Check
    90
  - Fuel System
    92
    
    Fuel Line Check
    92
    
    Water Separator Check
    93
  - Power Unit
    93
    
    Valve Clearance Measurement
    93
    
    Compression Pressure Measurement
    95
    
    Engine Oil Level Check
    96
    
    Engine Oil Change
    97
    
    Oil Filter Replacement
    98
    
    Air Filter Element Check
    99
    
    Spark Plug Check
    100
  - Electrical
    102
    
    Battery Check
    102
  - Jet Pump Unit
    104
    
    Jet Pump Unit Check
    104
  - Bilge Pump
    105
    
    Bilge Strainer Check
    105
    
    Electric Bilge Pump Strainer Check
    106
  - General
    106
    
    Drain Plug Check
    106
    
    Throttle Valve and Engine Internal Components
    106
    
    Lubrication Points
    107
Chapter 4 Fuel System

111
- Fuel Tank Removal
  112
- Fuel Tank, Fuel Pump Module, and Fuel Hose
  112
- Fuel Hose Disconnection
  116
- Fuel Pump Module Removal
  116
- Fuel Sender Removal
  117
- Check Valve Check
  118
- Rollover Valve Check
  118
- Fuel Filler Neck and Hose Check
  119
- Fuel Line Check
  119
- Fuel Pump Module Check
  119
- Fuel Tank Check
  119
- Fuel Injector Check
  120
- Fuel Injector Installation
  120
- Fuel Sender Installation
  120
- Fuel Hose Connection
  121
- Fuel Pump Module Installation
  121
- Fuel Pressure Measurement
  122
Chapter 5 Power Unit

123
- Powr
  123
- Pump
  124
- Engine Unit Removal 1
  126
- Hood
  126
  - Breather Assembly Check
    142
    
    Engine Mount Check
    142
    
    Engine Unit Installation
    143
  - Muffler
    150
    
    Muffler Disassembly
    150
    
    Exhaust Pipe 3 Installation
    152
    
    Exhaust Pipe 3 Removal
    152
    
    Muffler Check
    152
    
    Thermo Sensor Check
    152
  - Electrical Box and Starter Motor
    153
    
    Electrical Box and Starter Motor Removal
    153
  - Air Cooler, Supercharger, and Throttle Body Assembly
    156
    
    Air Cooler and Supercharger Removal
    156
    
    Intake Assembly Removal
    159
    
    Intake Disassembly
    161
    
    Air Cooler Check
    162
    
    Intake Manifold Check
    163
    
    Supercharger Check
    163
    
    Throttle Body Assembly Check
    163
    
    Intake Manifold Installation
    164
    
    Supercharger Installation
    164
    
    Air Cooler Intake Hose Installation
    165
    
    Boost Pipe Installation
    166
  - Oil Cooler, Oil Pump Assembly, and Drive Gear
    167
    
    Oil Cooler and Oil Pump Assembly Removal
    167
    
    Drive Gear Assembly Removal
    171
    
    Drive Gear Disassembly
    171
    
    Oil Cooler Assembly Check
    172
    
    Drive Gear Check
    173
    
    Idle Gear Check
    173
    
    Oil Pump Assembly Check
    173
    
    Drive Gear Clutch Check
    174
    
    Oil Pump Drive Gear Assembly
    174
    
    Drive Gear Assembly Installation
    175
    
    Oil Pump Assembly Installation
    176
  - Camshaft
    177
    
    Cylinder Head Cover Removal
    177
    
    Camshaft and Timing Chain Removal
    178
    
    Camshaft Removal
    181
    
    Camshaft Check
    183
    
    Camshaft Sprocket Check
    185
    
    Timing Chain Check
    185
    
    Timing Chain Tensioner Check
    185
    
    Camshaft Installation
    186
    
    Cylinder Head Cover Installation
    188
    
    Valve Clearance Adjustment
    189
  - Cylinder Head
    192
    
    Cylinder Head Assembly Removal
    192
    
    Cylinder Head Disassembly
    192
    
    Cylinder Head Assembly Removal
    194
    
    Cylinder Head Check
    194
    
    Valve Removal
    194
    
    Valve Check
    195
    
    Valve Spring Check
    195
    
    Valve Guide Check
    197
    
    Valve Guide Removal
    197
    
    Valve Guide Installation
    198
    
    Valve Seat Check
    199
    
    Valve Seat Refacing
    200
    
    Valve Installation
    203
    
    Cylinder Head Installation
    204
    
    Drive Coupling Removal
    208
    
    Flywheel Magneto Removal
    208
    
    Bearing Removal
    209
    
    Idle Gear and Shaft Check
    209
    
    Starter Clutch Check
    210
    
    Transfer Shaft Check
    210
    
    Bearing Installation
    211
    
    Oil Seal Installation
    211
    
    Flywheel Magneto Installation
    212
    
    Generator Cover Assembly
    212
    
    Drive Coupling Installation
    214
  - Oil Separator Tank and Oil Pan
    215
    
    Oil Separator Tank and Oil Pan Removal
    215
    
    Oil Pan Disassembly
    219
    
    Oil Pan Check
    220
  - Crankcase, Connecting Rod, and Piston
    222
    
    Connecting Rod and Piston Removal
    224
    
    Crankcase Disassembly
    224
    
    Anode Check
    225
    
    Crankcase Check
    225
    
    Piston Check
    226
    
    Piston Ring Check
    227
    
    Piston Pin Check
    228
    
    Connecting Rod Check
    229
    
    Cylinder Check
    229
    
    Crankshaft Check
    230
    
    Crankshaft Pin Oil Clearance Check
    230
    
    Crankshaft Journal Oil Clearance Check
    233
    
    Connecting Rod and Piston Installation
    236
    
    Crankcase Assembly
    238
  - Cooling Water
    240
    
    Cooling Water Hose Routing
    240
    
    Thermostat Removal
    241
    
    Cooling Water Line Check
    242
    
    Thermostat Check
    242
Pump Chapter 6 Jet Pump Unit

244
- Chapter 6 Intake Grate and Ride Plate Removal
  
  246
  - Intake Grate and Ride Plate
    246
  - Jet Pump Unit
    246
    
    Jet Pump Unit Removal
    247
    
    Jet Pump Unit Installation
    250
  - Reverse Gate
    251
    
    Reverse Gate Removal
    251
  - Jet Thrust Nozzle and Nozzle Ring
    253
    
    Jet Thrust Nozzle and Nozzle Ring Removal
    253
  - Impeller Duct and Impeller Housing
    254
    
    Impeller Duct and Impeller Housing Removal
    254
  - Impeller Duct and Drive Shaft
    255
    
    Impeller Duct and Drive Shaft Disassembly
    255
    
    Drive Shaft Removal
    257
    
    Drive Shaft Check
    259
    
    Impeller Check
    259
    
    Impeller Housing Check
    259
    
    Drive Shaft Installation
    260
    
    Impeller Duct and Impeller Housing Installation
    262
  - Transom Plate and Hoses
    264
    
    Transom Plate Installation
    266
    
    Water Hose Check
    266
  - Jet Pump
    266
  - Intermediate Housing
    270
    
    Driven Coupling Removal
    270
    
    Intermediate Drive Shaft Removal
    270
    
    Intermediate Housing Removal
    270
    
    Bearing Removal
    271
    
    Intermediate Drive Shaft and Grease Hose Check
    271
    
    Oil Seal Removal
    271
    
    Bearing Installation
    272
    
    Driven Coupling and Intermediate Housing Check
    272
    
    Oil Seal Installation
    273
    
    Driven Coupling Installation
    274
    
    Intermediate Housing Installation
    274
Chapter 7 Electrical System

276
- Electrical Components
  278
- Electrical Box
  280
  - Electrical Components
    280
  - Fuse Box Disassembly
    283
- Electrical Analysis
  286
  - Check Using the YDIS
    286
  - Input Voltage Measurement
    287
  - Peak Voltage Measurement
    287
- Ignition System
  288
  - Ignition Coil
    288
  - Pickup Coil
    291
- Charging System
  292
  - Stator Coil
    292
  - Rectifier Regulator
    294
- Control System
  296
  - Oil Pressure Switch
    296
  - Thermoswitch
    297
  - Thermo Sensor
    299
  - Engine Temperature Sensor
    300
  - Intake Air Temperature Sensor
    301
  - Intake Air Pressure Sensor
    303
  - Knock Sensor
    305
  - Throttle Position Sensor
    305
  - Accelerator Position Sensor
    308
  - Electronic Throttle Valve Relay
    312
  - Cam Position Sensor
    313
  - Slant Detection Switch
    314
  - Steering Sensor
    315
  - Reverse Sensor
    316
  - Right Handlebar Switch Assembly
    317
  - ECM Circuit
    319
  - Earth Plate
    320
  - Electric Bilge Pump
    320
- Fuel System
  321
  - Fuel Injector
    321
  - Fuel Pump Module
    323
- Starting System
  324
  - Fuse
    324
  - Left Handlebar Switch Assembly
    325
  - Main and Fuel Pump Relay
    326
  - Starter Relay
    328
- Starter Motor
  330
  - Starter Motor Operation
    333
  - Armature
    333
  - Brush Holder
    335
  - Gear Cover
    335
  - Rear Cover
    336
  - Starter Motor Assembly
    336
- Remote Control System
  336
  - Transmitter Registration
    336
  - Remote Control Transmitter
    337
  - Remote Control Receiver
    340
- Indication System
  341
  - Multifunction Meter
    341
  - Operation Button Assembly
    342
  - Compass Display (FX Cruiser SHO)
    344
  - Air Temperature Display (FX Cruiser SHO)
    345
  - Water Temperature Display (FX Cruiser SHO)
    345
  - Speed Sensor
    346
  - Digital Speedometer Display (FX SHO)
    347
  - Digital Speedometer Display (FX Cruiser SHO)
    348
  - Fuel Level Meter Display and Fuel Level Warning Indicator
    349
  - Check Engine Warning Indicator
    349
  - Diagnostic Display
    350
  - Oil Pressure Warning Indicator
    350
  - Engine Overheat Warning Indicator
    351
  - Buzzer
    351
Hood Chapter 8 Hull and Hood

354
- Chapter 8
  
  356
  - Handlebar
    356
  - Steering Pad Removal (FX SHO)
    356
  - Steering Pad Removal (FX Cruiser SHO)
    357
  - Handlebar Holder Removal
    358
  - Handlebar Assembly Removal
    359
  - Handlebar Check
    363
  - QSTS Grip and Converter
    367
    
    QSTS Grip and Converter Disassembly
    367
    
    QSTS Cable Removal
    369
    
    QSTS Check
    369
    
    QSTS Cable Installation
    370
  - Front Hood
    372
    
    Front Hood Removal
    372
    
    Damper Check
    375
    
    Mirror Assembly Installation
    375
    
    Mirror Disassembly
    375
    
    Rivet Installation
    376
    
    Rivet Removal
    376
    
    Center Cover Removal
    380
  - Steering Master
    384
    
    Steering Master Removal
    384
    
    Spring Installation
    389
    
    Steering Master Component Check
    389
    
    Rubber Seal Installation
    390
  - Remote Control Cables and Speed Sensor Lead
    391
    
    Remote Control Cables and Speed Sensor Lead Removal
    391
    
    Steering Cable Installation (Steering Master End)
    393
    
    Shift Cable Installation (Shift Lever End)
    394
    
    Steering Cable Installation (Jet Pump End)
    394
    
    Shift Cable Installation (Jet Pump End)
    395
  - Seats and Hand Grip
    398
    
    Seat and Hand Grip Removal
    398
    
    Seat Lock Check
    400
  - Exhaust System
    401
    
    Exhaust System and Battery Removal
    401
    
    Exhaust System Check
    404
  - Deck and Hull
    405
    
    Drain Plug Check
    409
    
    Front Protector 1 Installation
    409
    
    Pull-Up Cleat Cover Installation (FX Cruiser SHO)
    409
    
    Reboarding Step Installation
    409
    
    Introduction
    412
    
    Ydis
    412
    
    Engine Unit Trouble Analysis
    417
    
    Using the YDIS for Engine Unit Trouble Analysis
    417
    
    Self-Diagnosis
    418
    
    Diagnostic Code Table
    419
    
    Diagnostic Code and Checking Step
    420
    
    Engine Unit Trouble Analysis (Diagnostic Code Not Detected)
    426
    
    Trouble Analysis Chart
    426
- Chapter 9
  
  412
  - Features
    412
  - Functions
    412

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